Quick Start Guide

ManualsBrandsToro ManualsDrillToro 23803

FormNo.3412-311RevA

2226DirectionalDrill

ModelNo.23803—SerialNo.400000000andUp

QuickStartGuide

Thismachineisaprototypeunit.

Safety

Improperuseormaintenancebytheoperatorcan

resultininjury.Toreducethepotentialforinjury,

complywiththesesafetyinstructionsandthesafety

instructionthroughoutthisdocument,denotedbythe

safety-alertsymbol

,whichmeans:

Caution

W ar ning

Danger

—personalsafetyinstruction.Failureto

complywiththeinstructionmayresultinpersonalinjury

ordeath.

Thisproductiscapableofamputatinghandsandfeet.Follow

allsafetyinstructionstoavoidseriousinjuryordeath.

Theowner/usercanpreventandisresponsibleforaccidents

orinjuriesoccurringtopeople,ordamagetoproperty.

Important:Beforeoperatinginanareawith

high-voltagelinesorcables,contacta“One-CallSystem

Directory”service.IntheUSA,call811oryourlocal

utilitycompany.Ifyoudonotknowyourlocalutility

company’sphonenumber,callthenationalnumber

(USAandCanadaonly)at1-888-258-0808.Also,contact

anyutilitycompaniesthatarenotparticipantsofthe

“One-CallSystemDirectory”service.

•Readandunderstandthecontentsofthemanualbefore

youstartthemachine.Makesureeveryoneusingthis

machineknowshowtouseitandunderstandsthe

warnings.

•Donotputhandsorfeetnearmovingcomponentson

themachine.

•Keepbystandersasafedistancefromthemachine.

•Donotoperatemachinewithoutallguardsandother

safetyprotectivedevicesinplaceandworkingonthe

machine.

•Keepchildrenoutoftheoperatingareaandunderthe

watchfulcareofaresponsibleadultotherthanthe

operator.Neverallowchildrentooperatethemachine.

•Shutthemachineoffbeforeservicing,fueling,or

unplugging.

Training

•ReadtheOperator'sManualandothertrainingmaterial.

Note:Iftheoperator(s)ormechanic(s)cannotread

English,itistheowner'sresponsibilitytoexplainthis

materialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Donotletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof

theoperator.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform

thejob.Onlyuseaccessoriesandattachmentsapproved

bythemanufacturer.

•Wearappropriateclothing;includingahardhat,safety

glasses,longpants,safetyshoes,andhearingprotection.

•Tiebacklonghair.Donotwearjewelry.Secureloose

clothing.

•Inspecttheareawheretheequipmentistobeusedand

ensurethatallobjectsareremovedfromthemachine

beforeuse.

•Useextracarewhenhandlingfuels.Theyareammable

andvaporsareexplosive.

–Useonlyanapprovedcontainer.

–Donotremovethefuelcaporaddfuelwiththe

enginerunning.Allowtheenginetocoolbefore

refueling.Donotsmokenearthemachinewhenthe

engineisrunning.

–Donotrefuelordrainthemachineindoors.

•Checkthattheoperator'spresencecontrols,safety

switches,andshieldsareattachedandfunctioning

properly.Donotoperatethemachineunlesstheyare

functioningproperly.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3412-311*A

Summary of content (32 pages)

PAGE 1
Form No. 3412-311 Rev A 2226 Directional Drill Model No. 23803—Serial No. 400000000 and Up Quick Start Guide This machine is a prototype unit. Safety Training Improper use or maintenance by the operator can result in injury. To reduce the potential for injury, comply with these safety instructions and the safety instruction throughout this document, denoted by the safety-alert symbol , which means: Caution, Warning, or Danger—personal safety instruction.
PAGE 2
General Operation • Operate the drive pendant alongside the machine outside • Do not run the engine in an enclosed area. • Do not operate without the guards securely in place. Be • Keep all bystanders away while moving the machine. • • • • • • of the danger zone (Figure 1). sure all interlocks are attached, adjusted, and functioning properly. Do not change the engine governor setting or overspeed the engine. Keep away from moving machine parts and pipes.
PAGE 3
Drilling Safety includes where a person can be reached by operational movement of the machine, its working devices, auxiliary equipment, or swinging/falling equipment. Ensure that no one approaches a pipe while it is spinning. The pipe can snag on clothing and cause amputation or death. Always engage the Exit-side Lockout before anyone approaches the front of the machine, bit, reamer, or pipe.
PAGE 4
Utility Line Color Refer to the following table for the proper utility line and the corresponding utility line color (USA and Canada).
PAGE 5
Maintenance and Storage – Do not store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. • Do not touch parts which may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service. – Do not fill a container while it is inside a vehicle, trunk, pick-up bed, or any surface other than the ground. • Lower the thrust frame, stop the engine, and remove the key.
PAGE 6
Product Overview g194439 Figure 3 1. Drill carriage 6. Right Stabilizer 2. Zap alert strobe 7. Rear hood 3. Operator seat 8. Front hood 4. Control panel 9. Track 5. Thrust frame g194440 Figure 4 1. Pipe holder 3. Left stabilizer 2.
PAGE 7
g194441 Figure 5 1. Drill carriage 4. Upper wrench 2. Drill spindle 5. Lower wrench 3. Thrust frame 6.
PAGE 8
Operation You drill the bore in three stages: A. Entry Understanding Horizontal Directional Drilling In the entry phase of the bore, you push the drill bit and head into the ground at an angle of up to 16 degrees. After pushing in one or more pipes, you begin drilling down and forward until you reach the desired depth or depth-gauge hole (if used).
PAGE 9
Gathering Site Information DANGER Contacting underground hazards with the machine while drilling or reaming can cause explosion, electrocution, breathing problems, severe trauma, and death to you or bystanders. Planning the Initial Route Before you can begin boring, you need to plan the route you will bore and prepare as follows: – Ensure that all personnel at the job site wear personal protective equipment including a hard hat, eye protection, and hearing protection.
PAGE 10
– Electrical power lines – Crystalline silica and other dust If you will be drilling through or cutting concrete, sand, or other substances that create dusts or fumes, you need to ensure that you and all workers wear breathing protection to protect your lungs from the dust. DANGER Drilling into an electric power line will cause the machine to become electrified and may electrocute you or any bystanders. ◊ Keep bystanders and spectators away from the job site, including the complete bore path.
PAGE 11
Planning the Bore Path Before setting up the job site, you need to plan the bore path, including the following: 1 4 3 2 5 g021764 g021764 Figure 6 1. Bore entry 4. Obstacle 2. Beginning-of-bore-at-depth point 5. End-of-bore-at-depth point and bore exit 3. Bore depth • Bore entry needed for steering the drill to the surface, typically 9 to 15 m (30 to 50 ft) from the end-of-the-bore-at-depth point. The is the location where you setup the machine and the drill bit enters the ground.
PAGE 12
1 g021765 g021765 Figure 7 1. 20 cm (8 inches) This flexibility is often rated in materials as a minimum bend radius, which is the radius of the circle formed if the material or pipes, connected together, were bent to form a giant circle. The minimum radius of a circle made with the pipe used with this machine is 36.6 m (102 ft). 1 2 • Entry pitch 3 g021767 g021767 The entry pitch is the angle at which the machine enters the ground.
PAGE 13
Note: The depths given in the following table are for 3 m (10 ft) of combined drill head and pipe. As you steer up, the pitch of the steered section will change and can be monitored with the receiver. Use the following table to identify how many lengths of pipe will be necessary to insert and steer to the beginning point and help you choose an entry point.
PAGE 14
Given the above information, you can calculate the number of rods required to reach your beginning point at the appropriate depth. Toro recommends that you start the entry point a distance back from your beginning-at-depth point by the same distance as the length of pipes you will need to reach that point. This will ensure that you have enough extra space so you will not need to over-steer and damage the pipes.
PAGE 15
• You insert the first 3 m (10 ft) of drill bit/pipe into the The following example illustrates the process given an installation using the machine at an 18% pitch on level ground: ground with no steering. The end of the drill bit will be 53 cm (21 inches) deep (Figure 11). 6 1 2 3 4 5 g021769 g021769 Figure 11 1. 18% pitch 3. 96 cm (38 inches 5. 119 cm (47 inches) 2. 53 cm (21 inches) 4. 114 cm (45 inches) 6. 10.
PAGE 16
Understanding and Using the Exit-side-lockout System (Standard Range) button sends a signal to the receiver that allows the machine operator to reset the system and restore the thrust and rotary functions.
PAGE 17
Indicator Light State Meaning Green light is blinking rapidly The transmitter is transmitting to the base unit Green light is illuminated without blinking A button on the transmitter is currently pressed Yellow light is blinking slowly The batteries are low; change the batteries. If you do not change the batteries soon, the handheld will power down. Red light is blinking The transmitter is actively receiving messages from the base unit.
PAGE 18
Preparing the Job Site and the Machine complete, the Yellow light turns off, the Red light begins flashing, and the Green light illuminates. All lights remain as mentioned until you release the button. 8. Release the On button. Before drilling, prepare the job site and machine as follows: The Red light turns off and the Green light flashes for a few seconds. • Mark and prepare the bore path Planning the Bore Path (page 11).
PAGE 19
Testing the Zap-Alert System The Zap-Alert system is an electric strike sensing device on the machine that triggers a strobe light and audible alarm in the event that the drill bit, reamer, or stake breaks into an energized power line. In the event of an electric strike, the machine will become energized, setting off the alarm. DANGER If the Zap-Alert system activates while drilling, the machine, except for the operator’s platform, will become energized.
PAGE 20
7. Disconnect the alligator clips from the grounding stud and the machine. WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. 8. Store the grounding stake in the holder on the operator platform as shown in Figure 18. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep fuel away from eyes and skin.
PAGE 21
Starting/Stopping the Engine DANGER To start the engine, complete the following: In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. 1. Open the front hood. 2. Turn the battery disconnect switch to the On position. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. 3. Close and latch the hood. • Do not fill the fuel tank inside an enclosed trailer.
PAGE 22
Loading and Unloading the Machine 10. Remove the block from the trailer tires, and stow them with the machine for use when unloading it. WARNING 11. After driving a few miles, pull over and check to ensure that all chains are still tight and that the machine has not moved. Moving a machine of this size on a trailer over public roads carries risks to those around the machine if it should come loose, be involved in an accident, or hit a low hanging structure.
PAGE 23
g023073 Figure 21 g022373 Figure 23 3. Insert the sonde beacon with the forward end toward the drill bit into the sonde housing (Figure 22). 1. Thrust frame 2. Stake-down plate 7. Lower the rear stabilizers until they contact the ground firmly, or until the desired entry angle is achieved (Figure 24). Note: The rear of the tracks should just start to lift off the ground. Note: If the ground is soft, place timber below the stabilizers, and lower the stabilizers. g023060 Figure 22 1. Sonde housing 3.
PAGE 24
Setting Up the Pump to Use a Natural Water Source called drilling fluid or “Mud”, through the pipe and into the bore. This drilling fluid, or “Mud”, does the following for your bore: • Lubricates the drill head To set up a pump to use a natural water source, you must ensure that you use the Y-screen to filter all materials other than water. • Loosens the soil into which the drill is cutting To install the Y-screen perform the following tasks: • Penetrates and binds loose soil to keep them from 1.
PAGE 25
Drilling the Bore DANGER If the Zap-Alert system activates while drilling, the machine, except for the operator’s platform, will become energized. If you step off the operator platform or if someone touches the machine or wet ground near the machine or in the bore, you or they could be electrocuted causing serious injury or death. • Test the Zap-Alert system before drilling. • Deploy the grounding stake before drilling. Ensure that the stake is fully inserted into moist soil.
PAGE 26
3. When the area is clear of people, disable the exit-side lockout using the exit-side-lockout transmitter (the OK-to-Drill light on the control panel should illuminate); press the exit-side-lockout, reset switch on the control panel. 4. Pull the drill pipe and lead bar back through the pipe guide and into the wrenches, aligning the thickened upper joint of the lead bar with the upper wrench (Figure 30). Important: Do not clamp the wrench on the body of a pipe or it may damage the pipe.
PAGE 27
the female end of the previous pipe. Tighten the joint until you reach no more than 2,304 N-m (1,700 ft-lb). disconnect from each other and may be disconnected underground. 12. Release and retract the pipe gripper, rotating it all the way out past the third row of pipes. 1. When the area is clear of people, disable the exit-side lockout using the exit-side-lockout transmitter (the OK-to-Drill light on the control panel should illuminate); press the exit-side-lockout, reset switch on the control panel.
PAGE 28
• Cast cone packer—Use this reamer in soils that pack pressure, and increase the drilling fluid flow. If the drill head is entering a soil type other than what it is designed for, that can also raise temperature. Assess the situation and pull out the drill head and change it if necessary. easily, such as soft clay, peat, and loam, to pack the sides of the bore, maintaining the bore opening. • Fluted reamer—Use this reamer in hard clay and rocky soils; it combines the features of the other two reamers.
PAGE 29
Removing Drill Pipes 13. Move the drill carriage back until the male-pipe threads just clear the female end of the lower pipe, then close the upper wrench onto the shoulder of the pipe, but not on the threads. 1. Using the exit-side-lockout transmitter, enable the exit side lockout. 2. Install a drill-pipe wiper around the pipe and into the retaining bracket on the front of the machine. 14. Rotate the drill spindle counterclockwise until the upper-pipe joint is loose but not separated.
PAGE 30
5. Remove and store the last pipe; refer to Removing Drill Pipes (page 29). 6. Leave the lead bar clamped in the lower wrench, but do not connect the drill spindle to the lead bar. 7. Remove the reamer from the end of the lead bar as directed by the reamer manufacturer. 8. Release the lower wrench and pull the lead bar out of the pipe guide.
PAGE 31
Filling the TJC Applicator Adjusting the TJC-spray Volume 1. Stop the machine and stop the engine. To adjust the volume of thread-joint compound that is delivered by the applicator, complete the following: 2. Open the stake-down-guard door. 3. Loosen the wing nuts securing the cover straps to the machine (Figure 35). 1. Loosen the jam nut on the adjustment bolt located on top of the TJC-applicator piston (Figure 34). 1 2 1 3 2 3 4 5 g021846 g021846 g021845 Figure 35 g021845 Figure 34 1.
PAGE 32